GB1571276A - Method for producing a pole piece for a generator - Google Patents
Method for producing a pole piece for a generator Download PDFInfo
- Publication number
- GB1571276A GB1571276A GB1283478A GB1283478A GB1571276A GB 1571276 A GB1571276 A GB 1571276A GB 1283478 A GB1283478 A GB 1283478A GB 1283478 A GB1283478 A GB 1283478A GB 1571276 A GB1571276 A GB 1571276A
- Authority
- GB
- United Kingdom
- Prior art keywords
- workpiece
- hole
- centre
- annular projection
- pole piece
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 238000000034 method Methods 0.000 claims description 34
- 241000239290 Araneae Species 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 8
- 238000004080 punching Methods 0.000 claims description 7
- 238000005452 bending Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 238000004513 sizing Methods 0.000 claims description 3
- 229910000655 Killed steel Inorganic materials 0.000 claims description 2
- 229910001327 Rimmed steel Inorganic materials 0.000 claims description 2
- 238000009966 trimming Methods 0.000 claims 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/021—Magnetic cores
- H02K15/022—Magnetic cores with salient poles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/28—Making machine elements wheels; discs
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
- Iron Core Of Rotating Electric Machines (AREA)
Description
(54) METHOD FOR PRODUCING A POLE PIECE FOR A
GENERATOR
(71) We, AIDA ENGINEERING
LIMITED, a Japanese Company of No.
2-10 Ohyama-cho, Sagamihara-shi, Kanagawa, Japan, do hereby declare the invention for which we pray that a Patent may be granted to us and the method by which it is to be performed to be particularly described in and by the following statement: This invention relates to a method producing a pole piece for a generator which is referred to as an alternator in the automobile industry, that is, a pole piece for a generator which is adapted to be supplied with alternating current and to output the current as direct current.
In the generator of the above type, two pole pieces of this type are mounted on the generator rotor in a spaced relationship to each other. The prior art pole piece has been produced by mechanically cutting a slug or workpiece of a predetermined length off a round steel bar material and mechanically processing the workpieces requiring a relatvely high capacity press line including various mechanical cutting means which results in increase in production cost.
According to the present invention there is provided a method for producing a pole piece for a generator comprising cutting a workpiece of a predetermined length off a metal bar of round cross-section, extruding said workpiece so as to form an annular projection of reduced diameter at one end of said workpiece, deforming said workpiece so as to bulge radially and outwardly the remainder of the workpiece to form a bulged portion, deforming said bulged portion to form a centre disc portion from which extends radially outwardly a plurality of spiders each of which is integrally connected to the centre disc portion, punching a centre through hole in said disc portion and bending said spiders to that they extend in a direction parallel to the common axis of said annular projection and center through hole and so that they are located on the same side of the centre disc portion as the annular projection.
Accordingly, all the processing steps of the present invention with the exception of initially separating the workpiece from the metal bar do not require any mechanical cutting means and so enables a relatively low capacity press line to be used for performing the processing steps at room temperature.
Reference is now made to the accompanying drawings, in which: Figure 1 is a perspective view of a slug or workpiece for forming into a pole piece, the slug being separated from a steel bar of round cross-section in accordance with a first step of the method of the present invention;
Figure 2A is an end elevational view of one half portion of said slug after being processed in a second step of the method;
Figure 2B is an axial sectional view of said slug as shown in Figure 2a;
Figure 3A is an end elevational view of one half portoin of said slug after being processed in a third step of the method;
Figure 3B is an axial sectional view of said slug as shown in Figure 3A;
Figure 4A is an end elevational view of one half portion of said slug after being processed in a fourth step of the method;
Figure 4B is an axial sectional view of said slug as shown in Figure 4A;
Figure 5A is an end elevational view of one half portion of said slug after being processed in a fifth step of the method;
Figure 5B is an axial sectional view of said slug taken along the longitudinal axis of the slug as shown in Figure 5A;
Figure 6A is an end elevational view of one half portion of said slug after being processed in a sixth step of the method;
Figure 6B is an axial sectional view of said slug as shown in Figure 6A;
Figure 7A is an end elevational view of one half portion of said slug after being processed in a seventh step of the method;
Figure 7B is an axial sectional view of said slug as shown in Figure 7A;
Figure 8A is an end elevational view of one half portion of said slug after being processed in an eighth step of the method;
Figure 8B is an axial sectional view of said slug as shown in Figure 8A; and
Figure 9 is an axial-sectional view which shows a pair of pole pieces assembled on the rotary shaft of a generator with annular projections on the pole pieces abutting against each other.
Initially, a length suitable for forming a desired pole piece having a predetermined length is cut off a steel bar having a round cross-section by means of a suitable cutter to obtain a slug or workpiece 1 as shown in Figure 1.
The slug or workpiece 1 is processed in a press by extruding so as to form a reduced diameter annular projection 2 at one end of the workpiece 1 as shown in Figures 2A and 2B.
After the extruding step, the workpiece is deformed so as to bulge the remainder of the workpiece radially and outwardly so as to form a bulged portion 1' as shown in
Figures 3A and 3B.
The workpiece is then subjected to the fourth step in which the workpiece is processed so as to deform the bulged portion 1' into a disc portion 3 coaxial with the annular projection 2 and having a daimeter greater than that of the bulged portion and a thickness smaller than that of the bulged portion
1' and spiders 3' integral with and extending
radially and outwardly from the outer periphery of the disc portion as shown in Figures 4A and 4B.
The thus processed workpiece is then sub
jected to the fifth step in the method in which the spiders 3' are shaped or trimmed as shown in Figures SA and SB.
After the fifth step, the thus processed workpiece is turned upsidedown and an axial
through hole 4 is punched in the disc portion
3 to communicate with the opening defined
by the annular projection 2 as shown in
Figures 6A and 6B. In the forming of the
centre through hole 4 in the workpiece, it
is necessary to punch only the disc portion
3 which has been reduced in thickness
through the second step, thus, it will be
understood, providing economical service life
of the punch die employed in the punching
step.
After the sixth step, the workpiece is sub
jected to a bending step in a press to bend
the spiders 3' on the side of the annular
projection 2 of the workpiece ir; a direction
parallel to the common axis of the centre or
axial through hole 4 and annular projection
2 as shown in Figures 7A and 7B. Finally,
the workpiece is subjected to a sizing step
to obtain a complete product or pole piece
5 as shown in Figures 8A and 8B.
As shown in Figure 9, in practice, a
pair of pole pieces 5, produced by the
method as mentioned hereinbefore are
mounted on the rotary shaft 6 of a genera
tor by means of the axial through holes 4,
with the annular projections 2, of the pole
pieces 5, abutting against each other to
thereby form the rotor assembly of the
generator. According to an embodiment
of the present invention, all the steps of
the method from the first step to he tlast step are performed at room temperature.
Since the annular projection 2 is formed by
extruding in the second step, the centring
of the workpiece in the succeeding steps
following the second step can be easily
achieved. In the sixth step of the method
for forming the axial through hole 4, since
it s necessary to punch only the reduced
thickness disc portion 3, the service life of
the punch die is increased and the hole 4
can be precisely formed with a smooth hole
surface. If the entire thickness of the work
piece including the annular projection 2
has to be punched, the service life of the die
employed in the punching of the centre
through hole 4 would be reduced.
And if the centre hole forming operation
is performed by the employment of a lathe
or other mechanical means, there will be
the problem that when the pole piece is
fitted on the rotary shaft, so-called "biting"
would occur because of the presence of
traces on the hole surface scored by the
cutting tool and the like can be effectively
elimnated by the present invention. And
the automation of the method of the present invention can be attained by a press line directly connected to the assembly line.
And the load applied to the presses em
ployed is relatively small and a relatively
small amount of scrap of material is generated in the steps of the method to there
by increase yield rate. Furthermore, by the
steps of the method according to the present invention, the material for the pole piece may be less expensive rimmed steel rather than expensive killed steel as conveniently
used in the prior art methods for producing pole pieces. Thus, the overall production cost can be reduced and labour expense can be saved.
WHAT WE CLAIM IS:
1. A method for producing a pole piece for a generator, comprising cutting a workpiece of a predetermined length off a metal bar of round cross-section, extruding said workpiece so as to form an annular projection of reduced diameter at one end of said workpiece, deforming said workpiece so as to bulge radially and outwardly the remainder of the workpiece to form a
**WARNING** end of DESC field may overlap start of CLMS **.
Claims (8)
- **WARNING** start of CLMS field may overlap end of DESC **.processed in a seventh step of the method; Figure 7B is an axial sectional view of said slug as shown in Figure 7A; Figure 8A is an end elevational view of one half portion of said slug after being processed in an eighth step of the method; Figure 8B is an axial sectional view of said slug as shown in Figure 8A; and Figure 9 is an axial-sectional view which shows a pair of pole pieces assembled on the rotary shaft of a generator with annular projections on the pole pieces abutting against each other.Initially, a length suitable for forming a desired pole piece having a predetermined length is cut off a steel bar having a round cross-section by means of a suitable cutter to obtain a slug or workpiece 1 as shown in Figure 1.The slug or workpiece 1 is processed in a press by extruding so as to form a reduced diameter annular projection 2 at one end of the workpiece 1 as shown in Figures 2A and 2B.After the extruding step, the workpiece is deformed so as to bulge the remainder of the workpiece radially and outwardly so as to form a bulged portion 1' as shown in Figures 3A and 3B.The workpiece is then subjected to the fourth step in which the workpiece is processed so as to deform the bulged portion 1' into a disc portion 3 coaxial with the annular projection 2 and having a daimeter greater than that of the bulged portion and a thickness smaller than that of the bulged portion 1' and spiders 3' integral with and extending radially and outwardly from the outer periphery of the disc portion as shown in Figures 4A and 4B.The thus processed workpiece is then sub jected to the fifth step in the method in which the spiders 3' are shaped or trimmed as shown in Figures SA and SB.After the fifth step, the thus processed workpiece is turned upsidedown and an axial through hole 4 is punched in the disc portion3 to communicate with the opening defined by the annular projection 2 as shown in Figures 6A and 6B. In the forming of the centre through hole 4 in the workpiece, it is necessary to punch only the disc portion3 which has been reduced in thickness through the second step, thus, it will be understood, providing economical service life of the punch die employed in the punching step.After the sixth step, the workpiece is sub jected to a bending step in a press to bend the spiders 3' on the side of the annular projection 2 of the workpiece ir; a direction parallel to the common axis of the centre or axial through hole 4 and annular projection2 as shown in Figures 7A and 7B. Finally, the workpiece is subjected to a sizing step to obtain a complete product or pole piece5 as shown in Figures 8A and 8B.As shown in Figure 9, in practice, a pair of pole pieces 5, produced by the method as mentioned hereinbefore are mounted on the rotary shaft 6 of a genera tor by means of the axial through holes 4, with the annular projections 2, of the pole pieces 5, abutting against each other to thereby form the rotor assembly of the generator. According to an embodiment of the present invention, all the steps of the method from the first step to he tlast step are performed at room temperature.Since the annular projection 2 is formed by extruding in the second step, the centring of the workpiece in the succeeding steps following the second step can be easily achieved. In the sixth step of the method for forming the axial through hole 4, since it s necessary to punch only the reduced thickness disc portion 3, the service life of the punch die is increased and the hole 4 can be precisely formed with a smooth hole surface. If the entire thickness of the work piece including the annular projection 2 has to be punched, the service life of the die employed in the punching of the centre through hole 4 would be reduced.And if the centre hole forming operation is performed by the employment of a lathe or other mechanical means, there will be the problem that when the pole piece is fitted on the rotary shaft, so-called "biting" would occur because of the presence of traces on the hole surface scored by the cutting tool and the like can be effectively elimnated by the present invention. And the automation of the method of the present invention can be attained by a press line directly connected to the assembly line.And the load applied to the presses em ployed is relatively small and a relatively small amount of scrap of material is generated in the steps of the method to there by increase yield rate. Furthermore, by the steps of the method according to the present invention, the material for the pole piece may be less expensive rimmed steel rather than expensive killed steel as conveniently used in the prior art methods for producing pole pieces. Thus, the overall production cost can be reduced and labour expense can be saved.WHAT WE CLAIM IS: 1. A method for producing a pole piece for a generator, comprising cutting a workpiece of a predetermined length off a metal bar of round cross-section, extruding said workpiece so as to form an annular projection of reduced diameter at one end of said workpiece, deforming said workpiece so as to bulge radially and outwardly the remainder of the workpiece to form abulged portion, deforming said bulged portion to form a centre disc portion from which extends radially outwardly a plurality of spiders each of which is integrally connected to the centre disc portion, punching a centre through hole in said disc portion and bending said spiders so that they extend in a direction parallel to the common axis of said annular projection and centre through hole and so that they are located on the same side of the centre disc portion as the annular projection.
- 2. The method according to Claim 1, in which all the steps of the method are performed at room temperature.
- 3. The method according to Claim 1 or 2, further including the step of trimming said spiders between said deforming step to form said centre disc portion and spiders and said punching step.
- 4. The method according to Claim 2 or 3, further including the step of finally sizing the workpiece after said bending step.
- 5. A method of producing a pole piece substantially as described with reference to the accompanying drawings.
- 6. A pole piece for a generator produced by the method according to any of the preceding claims.
- 7. A pole piece according to Claim 6 and substantially as described with reference to and as illustrated in Figures 7A, 7B, 8A, 8B and 9 of the accompanying drawings.
- 8. A generator including a pole piece according to Claim 6 or 7.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1283478A GB1571276A (en) | 1978-04-01 | 1978-04-01 | Method for producing a pole piece for a generator |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB1283478A GB1571276A (en) | 1978-04-01 | 1978-04-01 | Method for producing a pole piece for a generator |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB1571276A true GB1571276A (en) | 1980-07-09 |
Family
ID=10011997
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB1283478A Expired GB1571276A (en) | 1978-04-01 | 1978-04-01 | Method for producing a pole piece for a generator |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB1571276A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1995019062A1 (en) * | 1994-01-03 | 1995-07-13 | Ateliers Thome-Genot | Improved process for manufacturing alternator pole piece |
| WO2020012274A1 (en) * | 2018-07-13 | 2020-01-16 | Nidec Corporation | Rotor unit for a brushless electric motor having single-piece magnetic flux conductors |
-
1978
- 1978-04-01 GB GB1283478A patent/GB1571276A/en not_active Expired
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1995019062A1 (en) * | 1994-01-03 | 1995-07-13 | Ateliers Thome-Genot | Improved process for manufacturing alternator pole piece |
| LT4118B (en) | 1994-01-03 | 1997-03-25 | Thome Genot Atel | Improved process for manufacturing alternator pole piece |
| WO2020012274A1 (en) * | 2018-07-13 | 2020-01-16 | Nidec Corporation | Rotor unit for a brushless electric motor having single-piece magnetic flux conductors |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PS | Patent sealed | ||
| PCNP | Patent ceased through non-payment of renewal fee |